Capsules with internal channels, heat-not-burn (hnb) aerosol-generating devices, and methods of generating an aerosol

ABSTRACT

A capsule for an aerosol-generating device may include a housing defining inlet openings, outlet openings, and internal channels between the inlet openings and the outlet openings. The internal channels are configured to hold an aerosol-forming substrate. The housing is configured to facilitate a heating of the aerosol-forming substrate via conduction and/or convection so as to generate an aerosol.

BACKGROUND Field

The present disclosure relates to capsules, heat-not-burn (HNB)aerosol-generating devices, and methods of generating an aerosol withoutinvolving a substantial pyrolysis of the aerosol-forming substrate.

Description of Related Art

Some electronic devices are configured to heat a plant material to atemperature that is sufficient to release constituents of the plantmaterial while keeping the temperature below a combustion point of theplant material so as to avoid any substantial pyrolysis of the plantmaterial. Such devices may be referred to as aerosol-generating devices(e.g., heat-not-burn aerosol-generating devices), and the plant materialheated may be tobacco. In some instances, the plant material may beintroduced directly into a heating chamber of an aerosol-generatingdevice. In other instances, the plant material may be pre-packaged inindividual containers to facilitate insertion and removal from anaerosol-generating device.

SUMMARY

At least one embodiment relates to a capsule for a heat-not-burn (HNB)aerosol-generating device. In an example embodiment, the capsule mayinclude a housing defining inlet openings, outlet openings, and internalchannels between the inlet openings and the outlet openings. Theinternal channels are configured to hold an aerosol-forming substrate.The housing is configured to facilitate a heating of the aerosol-formingsubstrate via conduction and/or convection so as to generate an aerosol.

At least one embodiment relates to a heat-not-burn (HNB)aerosol-generating device. In an example embodiment, theaerosol-generating device may include a device body and a heatingassembly. The device body defines at least one slot configured toreceive a capsule containing an aerosol-forming substrate. The heatingassembly is configured to heat the capsule containing theaerosol-forming substrate to generate an aerosol. The heating assemblymay include a first heater and a second heater configured to sandwichthe capsule in between so as to heat the aerosol-forming substrate viaconduction. The heating assembly may further include an upstream heaterconfigured to heat the aerosol-forming substrate via convection.

At least one embodiment relates to a method of generating an aerosol. Inan example embodiment, the method may include engaging a capsule betweena first heater and a second heater. The capsule may define internalchannels holding an aerosol-forming substrate. The method mayadditionally include heating the aerosol-forming substrate viaconduction with the first heater and the second heater. Furthermore, themethod may include heating the aerosol-forming substrate via convection.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of the non-limiting embodimentsherein may become more apparent upon review of the detailed descriptionin conjunction with the accompanying drawings. The accompanying drawingsare merely provided for illustrative purposes and should not beinterpreted to limit the scope of the claims. The accompanying drawingsare not to be considered as drawn to scale unless explicitly noted. Forpurposes of clarity, various dimensions of the drawings may have beenexaggerated.

FIG. 1 is a perspective view of a capsule for an aerosol-generatingdevice according to an example embodiment.

FIG. 2 is a front view of the capsule of FIG. 1.

FIG. 3 is a side view of the capsule of FIG. 1.

FIG. 4 is an end view of the capsule of FIG. 1.

FIG. 5 is a partially exploded view of the capsule of FIG. 1.

FIG. 6 is an additionally exploded view of the capsule of FIG. 5.

FIG. 7 is a further exploded view of the capsule of FIG. 6.

FIG. 8 is a perspective view of an aerosol-generating device accordingto an example embodiment.

FIG. 9 is an exploded view of the aerosol-generating device of FIG. 8.

DETAILED DESCRIPTION

Some detailed example embodiments are disclosed herein. However,specific structural and functional details disclosed herein are merelyrepresentative for purposes of describing example embodiments. Exampleembodiments may, however, be embodied in many alternate forms and shouldnot be construed as limited to only the example embodiments set forthherein.

Accordingly, while example embodiments are capable of variousmodifications and alternative forms, example embodiments thereof areshown by way of example in the drawings and will herein be described indetail. It should be understood, however, that there is no intent tolimit example embodiments to the particular forms disclosed, but to thecontrary, example embodiments are to cover all modifications,equivalents, and alternatives thereof. Like numbers refer to likeelements throughout the description of the figures.

It should be understood that when an element or layer is referred to asbeing “on,” “connected to,” “coupled to,” “attached to,” “adjacent to,”or “covering” another element or layer, it may be directly on, connectedto, coupled to, attached to, adjacent to or covering the other elementor layer or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directlyconnected to,” or “directly coupled to” another element or layer, thereare no intervening elements or layers present. Like numbers refer tolike elements throughout the specification. As used herein, the term“and/or” includes any and all combinations or sub-combinations of one ormore of the associated listed items.

It should be understood that, although the terms first, second, third,etc. may be used herein to describe various elements, regions, layersand/or sections, these elements, regions, layers, and/or sections shouldnot be limited by these terms. These terms are only used to distinguishone element, region, layer, or section from another region, layer, orsection. Thus, a first element, region, layer, or section discussedbelow could be termed a second element, region, layer, or sectionwithout departing from the teachings of example embodiments.

Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,”“upper,” and the like) may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It should be understood thatthe spatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is turned over, elements described as “below” or “beneath” otherelements or features would then be oriented “above” the other elementsor features. Thus, the term “below” may encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

The terminology used herein is for the purpose of describing variousexample embodiments only and is not intended to be limiting of exampleembodiments. As used herein, the singular forms “a,” “an,” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“includes,” “including,” “comprises,” and/or “comprising,” when used inthis specification, specify the presence of stated features, integers,steps, operations, and/or elements, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, and/or groups thereof.

When the terms “about” or “substantially” are used in this specificationin connection with a numerical value, it is intended that the associatednumerical value includes a manufacturing or operational tolerance (e.g.,±10%) around the stated numerical value. Moreover, when the terms“generally” or “substantially” are used in connection with geometricshapes, it is intended that precision of the geometric shape is notrequired but that latitude for the shape is within the scope of thedisclosure. Furthermore, regardless of whether numerical values orshapes are modified as “about,” “generally,” or “substantially,” it willbe understood that these values and shapes should be construed asincluding a manufacturing or operational tolerance (e.g., ±10%) aroundthe stated numerical values or shapes.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which example embodiments belong. Itwill be further understood that terms, including those defined incommonly used dictionaries, should be interpreted as having a meaningthat is consistent with their meaning in the context of the relevant artand will not be interpreted in an idealized or overly formal senseunless expressly so defined herein.

Hardware may be implemented using processing or control circuitry suchas, but not limited to, one or more processors, one or more CentralProcessing Units (CPUs), one or more microcontrollers, one or morearithmetic logic units (ALUs), one or more digital signal processors(DSPs), one or more microcomputers, one or more field programmable gatearrays (FPGAs), one or more System-on-Chips (SoCs), one or moreprogrammable logic units (PLUs), one or more microprocessors, one ormore Application Specific Integrated Circuits (ASICs), or any otherdevice or devices capable of responding to and executing instructions ina defined manner.

FIG. 1 is a perspective view of a capsule for an aerosol-generatingdevice according to an example embodiment. Referring to FIG. 1, acapsule 100 for an aerosol-generating device includes a housingconfigured to hold an aerosol-forming substrate and to facilitate aheating of the aerosol-forming substrate via conduction so as togenerate an aerosol. As will be discussed in more detail herein, thehousing may define inlet openings for incoming air, outlet openings foroutgoing aerosol, and internal channels for the aerosol-formingsubstrate, with the internal channels being between the inlet openingsand the outlet openings.

In an example embodiment, the housing includes a body section 130, afirst end cap 110, and a second end cap 120. The first end cap 110 maybe secured to an upstream end of the body section 130, and the secondend cap 120 may be secured to a downstream end of the body section 130(or vice versa). In particular, the first end cap 110 and the second endcap 120 are configured to engage with the body section 130 such thateach of the inlet openings of the first end cap 110 are in fluidiccommunication with a corresponding outlet opening of the second end cap120 via a corresponding internal channel of the body section 130. Thefirst end cap 110 and the second end cap 120 may be formed of a suitableplastic (e.g., via molding) or metal (e.g., via deep drawing, such asdeep drawn aluminum). As used herein, “upstream” (and, conversely,“downstream”) is in relation to a flow of the aerosol, and “proximal”(and, conversely, “distal”) is in relation to an adult operator of thedevice during aerosol generation.

The first end cap 110 defines a plurality of first openings 112 as theinlet openings, and the second end cap 120 defines a plurality of secondopenings 122 (e.g., FIG. 5) as the outlet openings. The inlet openingsare configured to permit air to enter the capsule 100, and the outletopenings are configured to permit the aerosol to exit the capsule 100.The body section 130 defines the internal channels, which are in fluidiccommunication with the inlet openings and the outlet openings. Theinternal channels are configured to hold the aerosol-forming substrateand to extend along a longest dimension of the housing.

The capsule 100 may have a slab-like form to facilitate a heating of theaerosol-forming substrate therein via conduction. For instance, thehousing may have a length, a width, and a thickness that results in theslab-like form. The length of the housing extends from the upstream endface of the capsule 100 to the downstream end face of the capsule 100and, thus, includes the corresponding dimensions of the first end cap110 and the second end cap 120 extending beyond the body section 130.However, it should be understood that in an instance where the first endcap 110 and the second end cap 120 are configured to be seated so as tobe flush with the upstream rim and the downstream rim, respectively, ofthe body section 130 (so as to not extend beyond the body section 130),the length of the housing may just correspond to the length of the bodysection 130. The width of the housing extends orthogonally to the lengthand along the direction of alignment of the plurality of first openings112 (or the plurality of second openings 122). The thickness of thehousing extends orthogonally to the length and the width. Asillustrated, the length of the housing is greater than the width (e.g.,average width, maximum width), and the width is greater than thethickness (e.g., average thickness, maximum thickness). The internalchannels defined by the body section 130 extend in a direction of thelength.

FIG. 2 is a front view of the capsule of FIG. 1. Referring to FIG. 2,the length and the width of the housing are in view, while the thicknessis not in view. With regard to the width of the housing, the portions ofthe housing corresponding to the first end cap 110 and the second endcap 120 are wider than the portion of the housing corresponding to thebody section 130. However, in another instance, the first end cap 110and the second end cap 120 may be configured to be even with the sidewalls of the body section 130. In such an instance, the width of thehousing may be regarded as being uniform.

FIG. 3 is a side view of the capsule of FIG. 1. Referring to FIG. 3, thelength and the thickness of the housing are in view, while the width isnot in view. With regard to the thickness of the housing, the portionsof the housing corresponding to the first end cap 110 and the second endcap 120 are thicker than the portion of the housing corresponding to thebody section 130. However, in another instance, the first end cap 110and the second end cap 120 may be configured to be even with the frontand rear walls of the body section 130. In such an instance, thethickness of the housing may be regarded as being uniform. In an exampleembodiment, the thickness of the housing is configured to facilitate theuniform heating of the aerosol-forming substrate 160 (FIG. 5) within thecapsule 100.

FIG. 4 is an end view of the capsule of FIG. 1. Referring to FIG. 4, thefirst end cap 110 may have a shape resembling a rectangle with a pair ofopposing semicircular ends (e.g., elongated circle, obround,discorectangle) based on an upstream end view of the capsule 100.However, in another instance, the first end cap 110 may have arectangular shape with angular or rounded corners based on an upstreamend view of the capsule 100. As illustrated, the plurality of firstopenings 112 may be evenly spaced and arranged in a linear manner.Alternatively, in some instances, the plurality of first openings 112may be arranged in a staggered manner (e.g., zigzag arrangement).Furthermore, although the first end cap 110 is illustrated as definingseven first openings 112, it should be understood that exampleembodiments are not limited thereto. For instance, the first end cap 110may define more (e.g., eight) or less (e.g., six) openings based on thenumber of internal channels within the capsule 100.

FIG. 5 is a partially exploded view of the capsule of FIG. 1. Asillustrated, in addition to the first end cap 110 and the second end cap120, the capsule 100 may also include a corrugated structure 134 and acover 132 configured to contain the corrugated structure 134. In anexample embodiment, the combination of corrugated structure 134 and thecover 132 may be regarded as the body section 130. Additionally, thecover 132 may be a conductive cover (e.g., thermally conductive cover)that facilitates a heating of the aerosol-forming substrate 160 viaconduction. For instance, the cover 132 may be made of metal(s). Themetal(s) may include aluminum (e.g., aluminum or alloy thereof in a formof a foil). The aluminum may also be anodized aluminum.

In FIG. 5, the cover 132 is shown separately, while the first end cap110 and the second end cap 120 are engaged with the corrugated structure134. The first end cap 110 includes a plurality of first mating members114 configured to engage with the upstream end of the corrugatedstructure 134, while the second end cap 120 includes a plurality ofsecond mating members 124 configured to engage with the downstream endof the corrugated structure 134. In an example embodiment, the first endcap 110 and the second end cap 120 are identical structures and, thusinterchangeable. In such an instance, the first end cap 110 may beengaged with the downstream end of the corrugated structure 134, whilethe second end cap 120 is engaged with the upstream end of thecorrugated structure 134.

Each of the plurality of first mating members 114 has one of theplurality of first openings 112 extending therethrough, while theremainder of the plurality of first openings 112 extend through adjacentportions of the first end cap 110 between the plurality of first matingmembers 114. Similarly, each of the plurality of second mating members124 has one of the plurality of second openings 122 extendingtherethrough, while the remainder of the plurality of second openings122 extend through adjacent portions of the second end cap 120 betweenthe plurality of second mating members 124 (e.g., hidden from view inFIG. 5 but shown in FIG. 7).

FIG. 6 is an additionally exploded view of the capsule of FIG. 5.Referring to FIG. 6, the first end cap 110 is disengaged from theupstream end of the corrugated structure 134, while the second end cap120 is engaged with the downstream end of the corrugated structure 134.Each of the plurality of first mating members 114 and the plurality ofsecond mating members 124 has a shape configured for seating within acorresponding furrow or trough of the corrugated structure 134. Whenseated, each of the plurality of first mating members 114 and theplurality of second mating members 124 may also be separated from anadjacent mating member by a ridge or crest of the corrugated structure134.

As illustrated, the corrugated structure 134 may have a cross-sectionresembling a trapezoidal wave. In such an instance, each of theplurality of first mating members 114 and the plurality of second matingmembers 124 may have an inverted trapezoidal shape (e.g., invertedisosceles trapezoid) configured for seating within a correspondingfurrow or trough of the corrugated structure 134 (based on theorientation shown in FIG. 6). Additionally, the plurality of firstmating members 114 and the plurality of second mating members 124 on theends may have an inverted right-angled trapezoidal shape. Thus, theplurality of first mating members 114 may include two mating membersthat have an inverted isosceles trapezoidal shape and two mating membersthat have an inverted right-angled trapezoidal shape, while theplurality of second mating members 124 may similarly include two matingmembers that have an inverted isosceles trapezoidal shape and two matingmembers that have an inverted right-angled trapezoidal shape. However,it should be understood that other configurations are also possible. Forinstance, alternatively, the corrugated structure 134 may have across-section resembling a square wave, a triangle wave, a sawtoothwave, or a sine wave, and the plurality of first mating members 114 andthe plurality of second mating members 124 may be shaped accordingly.

FIG. 7 is a further exploded view of the capsule of FIG. 6. Referring toFIG. 7, the corrugated structure 134 is disengaged from both the firstend cap 110 and the second end cap 120. The corrugated structure 134 hasalternating ridges 136 and furrows 138 as the internal channelsconfigured to hold the aerosol-forming substrate. In an exampleembodiment, the internal channels provided by the ridges 136 and furrows138 are separate and independent conduits. It should be understood thata ridge 136 on the front side of the corrugated structure 134 shown inFIG. 7 would be a furrow 138 on the rear side of the corrugatedstructure 134. Conversely, a furrow 138 on the front side of thecorrugated structure 134 shown in FIG. 7 would be a ridge 136 on therear side of the corrugated structure 134.

In an example embodiment, the front side of the corrugated structure 134shown in FIG. 7 has three ridges 136 and four furrows 138, while therear side of the corrugated structure 134 has four ridges 136 and threefurrows 138. In such an instance, the corrugated structure 134 definesseven internal channels which correspond to the first openings 112(seven total) in the first end cap 110 and the second openings 122(seven total) in the second end cap 120. In particular, four internalchannels may be provided by the four furrows 138 on the front side ofthe corrugated structure 134 shown in FIG. 7, while three internalchannels may be provided by the three furrows 138 on the rear side ofthe corrugated structure 134.

As illustrated, each of the ridges 136 and furrows 138 of the corrugatedstructure 134 may have a coplanar surface between a pair of angledsurfaces. For instance, the coplanar surfaces on the front side of thecorrugated structure 134 shown in FIG. 7 may be in the form of threeridge top strips and four furrow bottom strips extending between thefirst end cap 110 and the second end cap 120. Similarly, the coplanarsurfaces on the rear side of the corrugated structure 134 may be in theform of four ridge top strips and three furrow bottom strips extendingbetween the first end cap 110 and the second end cap 120. The coplanarstrips may extend in parallel. It should be understood that the topportions of the ridges 136 on the front side of the corrugated structure134 shown in FIG. 7 will be the bottom portions of the furrows 138 onthe rear side of the corrugated structure 134. Conversely, the bottomportions of the furrows 138 on the front side of the corrugatedstructure 134 shown in FIG. 7 will be the top portions of the ridges 136on the rear side of the corrugated structure 134.

The corrugated structure 134 is formed of a suitable material havingsufficient rigidity to maintain the integrity of the ridges 136 and thefurrows 138 when the aerosol-forming substrate is loaded into theinternal channels of the capsule 100. For instance, the corrugatedstructure 134 may be formed of a plant-based sheet material (e.g.,cardboard such as concertina cardboard, paperboard, or molded pulp). Theplant-based sheet material may be fabricated from wood, bamboo, tobacco,and/or cannabis (e.g., bamboo and tobacco pulp). In another instance,the corrugated structure 134 may be formed of plastic or metal.

The cover 132 is configured to receive the corrugated structure 134 soas to surround the ridges 136 and furrows 138 when the capsule 100 isassembled. In an example embodiment, the ridges 136 and the furrows 138are configured to contact the opposing inner surfaces of the cover 132when the corrugated structure 134 is received within the cover 132. Theopposing end folds of the corrugated structure 134 may also contact theopposing inner sidewalls of the cover 132 when the corrugated structure134 is received within the cover 132. As a result, the corrugatedstructure 134 may have nine sections of contact with the cover 132,although example embodiments are not limited thereto. Additionally, thecover 132 is configured to receive the first end cap 110 and the secondend cap 120 such that at least the first mating members 114 and thesecond mating members 124, respectively, are within the cover 132 and,thus, hidden from view when the capsule 100 is assembled. Asillustrated, the cover 132 may be in a form of a box sleeve.

To assemble the capsule 100, the first end cap 110 may be engaged withthe corrugated structure 134 such that each of the plurality of firstmating members 114 is seated within a corresponding furrow 138. Thecorrugated structure 134 and the first end cap 110 may then be insertedinto the cover 132 until the flanged portion of the first end cap 110abuts the upstream rim of the cover 132. Alternatively, the corrugatedstructure 134 may be initially received within the cover 132 before thefirst end cap 110 is inserted to engage both the corrugated structure134 and the cover 132. In either instance, a portion of the upstream endof the corrugated structure 134 may be between (e.g., pressed between)the plurality of first mating members 114 and the cover 132. Theengagement between the first end cap 110 and the cover 132 may be via aninterference fit (which may also be referred to as a press fit orfriction fit). Furthermore, in lieu of or in addition to theinterference fit, the first end cap 110 may also be secured to the cover132 with an adhesive (e.g., glue) that has been deemed food-safe orotherwise acceptable by a regulatory authority.

Once the corrugated structure 134 and the first end cap 110 are engagedwith the cover 132, an aerosol-forming substrate may then be loaded intothe internal channels. As noted supra, the internal channels are definedby the body section 130, which includes the cover 132 and the corrugatedstructure 134. In particular, each internal channel may be regarded asbeing defined by a furrow 138 of the corrugated structure 134 and acorresponding inner surface of the cover 132. As a result, the fourfurrows 138 on the front side of the corrugated structure 134 shown inFIG. 7 and the corresponding inner surfaces of the cover 132 define fourinternal channels, while the three furrows 138 on the rear side of thecorrugated structure 134 and the corresponding inner surfaces of thecover 132 define three internal channels. In this manner, seven internalchannels may be defined by the corrugated structure 134 and the cover132.

In an example embodiment, one type of aerosol-forming substrate may beloaded into the capsule 100. In such an instance, the sameaerosol-forming substrate may be loaded into each of the internalchannels defined by the body section 130 of the capsule 100. In anotherexample embodiment, several types of aerosol-forming substrates may beloaded into the capsule 100. For instance, a first type ofaerosol-forming substrate may be loaded into a first group of theinternal channels (e.g., four internal channels on the front side of thecorrugated structure 134 shown in FIG. 7), while a second type ofaerosol-forming substrate may loaded into a second group of the internalchannels (e.g., three internal channels on the rear side of thecorrugated structure 134). In yet another example embodiment, a mixtureof different types of aerosol-forming substrates may be loaded into thesame internal channel for one or more of the internal channels definedby the body section 130 of the capsule 100. However, it should beunderstood that example embodiments are not limited thereto and thatother combinations are possible.

As discussed herein, an aerosol-forming substrate is a material orcombination of materials that may yield an aerosol. An aerosol relatesto the matter generated or output by the devices disclosed, claimed, andequivalents thereof. The material may include a compound (e.g.,nicotine, cannabinoid), wherein an aerosol including the compound isproduced when the material is heated. The heating may be below thecombustion temperature so as to produce an aerosol without involving asubstantial pyrolysis of the aerosol-forming substrate or thesubstantial generation of combustion byproducts (if any). Thus, in anexample embodiment, pyrolysis does not occur during the heating andresulting production of aerosol. In other instances, there may be somepyrolysis and combustion byproducts, but the extent may be consideredrelatively minor and/or merely incidental.

The aerosol-forming substrate may be a fibrous material. For instance,the fibrous material may be a botanical material. The fibrous materialis configured to release a compound when heated. The compound may be anaturally occurring constituent of the fibrous material. For instance,the fibrous material may be plant material such as tobacco, and thecompound released may be nicotine. The term “tobacco” includes anytobacco plant material including tobacco leaf, tobacco plug,reconstituted tobacco, compressed tobacco, shaped tobacco, or powdertobacco, and combinations thereof from one or more species of tobaccoplants, such as Nicotiana rustica and Nicotiana tabacum.

In some example embodiments, the tobacco material may include materialfrom any member of the genus Nicotiana. In addition, the tobaccomaterial may include a blend of two or more different tobacco varieties.Examples of suitable types of tobacco materials that may be usedinclude, but are not limited to, flue-cured tobacco, Burley tobacco,Dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco,specialty tobacco, blends thereof, and the like. The tobacco materialmay be provided in any suitable form, including, but not limited to,tobacco lamina, processed tobacco materials, such as volume expanded orpuffed tobacco, processed tobacco stems, such as cut-rolled orcut-puffed stems, reconstituted tobacco materials, blends thereof, andthe like. In some example embodiments, the tobacco material is in theform of a substantially dry tobacco mass. Furthermore, in someinstances, the tobacco material may be mixed and/or combined with atleast one of propylene glycol, glycerin, sub-combinations thereof, orcombinations thereof.

The compound may also be a naturally occurring constituent of amedicinal plant that has a medically-accepted therapeutic effect. Forinstance, the medicinal plant may be a cannabis plant, and the compoundmay be a cannabinoid. Cannabinoids interact with receptors in the bodyto produce a wide range of effects. As a result, cannabinoids have beenused for a variety of medicinal purposes (e.g., treatment of pain,nausea, epilepsy, psychiatric disorders). The fibrous material mayinclude the leaf and/or flower material from one or more species ofcannabis plants such as Cannabis sativa, Cannabis indica, and Cannabisruderalis. In some instances, the fibrous material is a mixture of60-80% (e.g., 70%) Cannabis sativa and 20-40% (e.g., 30%) Cannabisindica.

Examples of cannabinoids include tetrahydrocannabinolic acid (THCA),tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol(CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), andcannabigerol (CBG). Tetrahydrocannabinolic acid (THCA) is a precursor oftetrahydrocannabinol (THC), while cannabidiolic acid (CBDA) is precursorof cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) andcannabidiolic acid (CBDA) may be converted to tetrahydrocannabinol (THC)and cannabidiol (CBD), respectively, via heating. In an exampleembodiment, heat from a heater may cause decarboxylation so as toconvert the tetrahydrocannabinolic acid (THCA) in the capsule 100 totetrahydrocannabinol (THC), and/or to convert the cannabidiolic acid(CBDA) in the capsule 100 to cannabidiol (CBD).

In instances where both tetrahydrocannabinolic acid (THCA) andtetrahydrocannabinol (THC) are present in the capsule 100, thedecarboxylation and resulting conversion will cause a decrease intetrahydrocannabinolic acid (THCA) and an increase intetrahydrocannabinol (THC). At least 50% (e.g., at least 87%) of thetetrahydrocannabinolic acid (THCA) may be converted totetrahydrocannabinol (THC) during the heating of the capsule 100.Similarly, in instances where both cannabidiolic acid (CBDA) andcannabidiol (CBD) are present in the capsule 100, the decarboxylationand resulting conversion will cause a decrease in cannabidiolic acid(CBDA) and an increase in cannabidiol (CBD). At least 50% (e.g., atleast 87%) of the cannabidiolic acid (CBDA) may be converted tocannabidiol (CBD) during the heating of the capsule 100.

Furthermore, the compound may be or may additionally include anon-naturally occurring additive that is subsequently introduced intothe fibrous material. In one instance, the fibrous material may includeat least one of cotton, rayon, a combination thereof, or the like (e.g.,in a form of a gauze). In another instance, the fibrous material may bea cellulose material (e.g., non-tobacco and/or non-cannabis material).In either instance, the compound introduced may include nicotine,cannabinoids, and/or flavorants. The flavorants may be from naturalsources, such as plant extracts (e.g., tobacco extract, cannabisextract), and/or artificial sources. In yet another instance, when thefibrous material includes tobacco and/or cannabis, the compound may beor may additionally include one or more flavorants (e.g., menthol, mint,vanilla). Thus, the compound within the aerosol-forming substrate mayinclude naturally occurring constituents and/or non-naturally occurringadditives. In this regard, it should be understood that existing levelsof the naturally occurring constituents of the aerosol-forming substratemay be increased through supplementation. For example, the existinglevels of nicotine in a quantity of tobacco may be increased throughsupplementation with an extract containing nicotine. Similarly, theexisting levels of one or more cannabinoids in a quantity of cannabismay be increased through supplementation with an extract containing suchcannabinoids.

After the loading of the aerosol-forming substrate into the internalchannels, the second end cap 120 is inserted into the cover 132 toengage with the corrugated structure 134. In particular, the second endcap 120 may be inserted into the cover 132 until the flanged portion ofthe second end cap 120 abuts the downstream rim of the cover 132.Additionally, a portion of the downstream end of the corrugatedstructure 134 may be between (e.g., pressed between) the plurality ofsecond mating members 124 and the cover 132. The engagement between thesecond end cap 120 and the cover 132 may be via an interference fit.Furthermore, in lieu of or in addition to the interference fit, thesecond end cap 120 may also be secured to the cover 132 with an adhesivethat has been deemed food-safe or otherwise acceptable by a regulatoryauthority.

When the capsule 100 is assembled, the second mating members 124 of thesecond end cap 120 will be seated within the same furrows 138 of thecorrugated structure 134 as the first mating members 114 of the firstend cap 110. As a result, the first openings 112 extending through thefirst mating members 114 of the first end cap 110 will be in fluidiccommunication with the second openings 122 extending through the secondmating members 124 of the second end cap 120. Similarly, the firstopenings 112 extending between the first mating members 114 of the firstend cap 110 will be in fluidic communication with the second openings122 extending between the second mating members 124 of the second endcap 120. Accordingly, during aerosol generation, incoming air enteringthe capsule 100 via a first opening 112 in the first end cap 110 willflow through a corresponding internal channel and the aerosol-formingsubstrate being heated therein, thereby entraining the volatilesreleased from the aerosol-forming substrate to produce an aerosol thatis drawn out of the capsule 100 via a corresponding second opening 122in the second end cap 120 at the opposite downstream end of the internalchannel. In this manner, seven separate and independent air/aerosolstreams may be regarded as flowing through the capsule 100 duringaerosol generation by virtue of the seven internal channels definedtherein.

Although the assembly process above for the capsule 100 has beendiscussed as concluding with the engagement of the second end cap 120with the cover 132 and the corrugated structure 134, it should beunderstood that the assembly process may be reversed so as to insteadconclude with the engagement of the first end cap 110 with the cover 132and the corrugated structure 134. In any event, once assembled, thecapsule 100 may be as shown in FIG. 1. While not illustrated, a sealingstrip may also be applied to each of the upstream end face of the firstend cap 110 and the downstream end face of the second end cap 120 so asto cover the first openings 112 and the second openings 122,respectively, (e.g., in preparation for or during packaging) for thepurpose of preserving the organoleptic properties of the aerosol-formingsubstrate.

FIG. 8 is a perspective view of an aerosol-generating device accordingto an example embodiment. Referring to FIG. 8, an aerosol-generatingdevice 300 includes a device body 330 defining at least one slotconfigured to receive a capsule 200 containing an aerosol-formingsubstrate. The aerosol-generating device 300 additionally includes aheating assembly configured to heat the capsule 200 and theaerosol-forming substrate therein to generate an aerosol. The heatingassembly may include a first heater 310 and a second heater 320 (FIG. 9)configured to sandwich the capsule 200 in between so as to heat theaerosol-forming substrate via conduction. The first heater 310 and thesecond heater 320 may be configured to operate jointly or independently(e.g., so as to be capable of providing different heating profiles).Furthermore, the aerosol-generating device 300 may include a firstcoupler 340 defining an air inlet and a second coupler 350 defining anaerosol outlet. The capsule 200 in FIG. 8 may be the same as the capsule100 in FIGS. 1-7. As a result, the relevant disclosures above of thefeatures in common should be understood to apply to this section and maynot have been repeated in the interest of brevity.

FIG. 9 is an exploded view of the aerosol-generating device of FIG. 8.Referring to FIG. 9, the device body 330 of the aerosol-generatingdevice 300 defines a slot 332 (e.g., side slot for side loading)configured to receive the capsule 200 (FIG. 8). Additionally, the devicebody 330 of the aerosol-generating device 300 may define a front openingand a rear opening configured to expose the front and the rear,respectively, of the cover of the capsule 200 (when the capsule 200 isreceived within the device body 330) so as to permit an engagement withthe first heater 310 and the second heater 320, respectively. The devicebody 330 may also define an upstream opening (e.g., upstream slot) and adownstream opening (e.g., downstream slot) configured to accommodate thefirst end cap and the second end cap, respectively, of the capsule 200so as to permit an engagement with the first coupler 340 and the secondcoupler 350, respectively. In an example embodiment, the capsule 200may, alternatively, be inserted into the device body 330 through theupstream opening (e.g., bottom loading) and/or the downstream opening(e.g., top loading).

The cover, the first end cap, and the second end cap of the capsule 200may be as described in connection with the cover 132, the first end cap110, and the second end cap 120 of the capsule 100. Although notillustrated, it should be understood that the capsule 200 may alsoinclude a corrugated structure within, which may be as described inconnection with the corrugated structure 134 of the capsule 100. As aresult, the applicable details already discussed above will not berepeated in the interest of brevity.

In an example embodiment, the capsule 200 may be inserted into the slot332 such that the capsule 200 abuts the opposing closed side of thedevice body 330. The capsule 200 may then be engaged by the firstcoupler 340 and the second coupler 350. The first coupler 340 may definean elongated, narrow opening (e.g., first slit) configured to coincidewith at least the first openings in the first end cap of the capsule200. For instance, the length of the elongated, narrow opening of thefirst coupler 340 may be greater than the linear span of the collectivefirst openings in the first end cap of the capsule 200. Additionally,the width of the elongated, narrow opening of the first coupler 340 maybe less than the diameter of the first openings in the first end cap ofthe capsule 200. During the operation of the aerosol-generating device300, incoming air passes through the elongated, narrow opening of thefirst coupler 340 and then enters the capsule 200 via the first openingsin the first end cap.

Similarly, the second coupler 350 may define an elongated, narrowopening (e.g., second slit) configured to coincide with at least thesecond openings in the second end cap of the capsule 200. For instance,the length of the elongated, narrow opening of the second coupler 350may be greater than the linear span of the collective second openings inthe second end cap of the capsule 200. Additionally, the width of theelongated, narrow opening of the second coupler 350 may be less than thediameter of the second openings in the second end cap of the capsule200. During the operation of the aerosol-generating device 300, thegenerated aerosol exits the capsule 200 via the second openings in thesecond end cap and then continues through the elongated, narrow openingof the second coupler 350. From a structural perspective, the secondcoupler 350 may be identical to the first coupler 340, although exampleembodiments are not limited thereto.

The first heater 310 and the second heater 320 are configured tophysically contact the cover of the capsule 200 when the capsule 200 isfully engaged within the aerosol-generating device 300. In an exampleembodiment, the first heater 310 and the second heater 320 mayadditionally overlap with the first end cap and the second end cap ofthe capsule 200 without physically contacting the first end cap and thesecond end cap (by virtue of the intervening cover of the capsule 200).Furthermore, the engaging, inner surface of the first heater 310 isconfigured to interface with a majority (e.g., at least 80%) of thefirst face (e.g., front face) of the cover of the capsule 200.Similarly, the engaging, inner surface of the second heater 320 may beconfigured to interface with a majority (e.g., at least 80%) of theopposing second face (e.g., rear face) of the cover of the capsule 200.As a result, a desirable level of thermal contact may be established toheat the aerosol-forming substrate within the capsule 200 via conductionto generate an aerosol.

The first heater 310 and the second heater 320 may utilize resistiveheating elements and may be embodied as ceramic, silicone, wire, or meshheaters as known in the art. From a structural perspective, the firstheater 310 may be identical to the second heater 320, although exampleembodiments are not limited thereto. Furthermore, in some instances, theaerosol-generating device 300 may be configured such that the incomingair initially flows along the outer surface of the first heater 310and/or the outer surface of the second heater 320 (e.g., in a directionfrom the second coupler 350 to the first coupler 340) before passingthrough the first coupler 340. In another instance, a separate upstreamheater may be provided to heat the incoming air before it passes throughthe first coupler 340. In either instance, the incoming air may beheated (e.g., pre-heated) before passing through the first coupler 340and into the capsule 200 to heat the aerosol-forming substrate thereinvia convection.

While not illustrated, it should be understood that theaerosol-generating device 300 may include additionalstructures/components configured to provide the desired aestheticsand/or functionalities. For instance, the aerosol-generating device 300may include an external housing structure that is designed to bevisually appealing while sized to be portable and configured tofacilitate ease of handling (e.g., ergonomically-shaped for one-handedoperation). Also, within the external housing structure may be providedactuating mechanisms, a power source, and control circuitry. Theactuating mechanisms (e.g., rack and pinion arrangements and/orspring-loaded arrangements) may be configured to move the first coupler340, the second coupler 350, the first heater 310, and/or the secondheater 320 so as to engage the capsule 200. The actuating mechanisms mayalso provide a confirmatory feedback (e.g., audible click) to indicatethat the capsule 200 is properly inserted and engaged (e.g., locked-in).The power source may include one or more batteries (e.g., rechargeablebattery arrangement). Upon engagement of the capsule 200, the controlcircuitry may instruct the power source to supply an electric current tothe first heater 310 and the second heater 320. The instruction tosupply an electric current from the power source may be in response to amanual operation (e.g., button-activation) or an automatic operation(e.g., puff-activation). As a result of the electric current, thecapsule 200 may be conductively heated by the first heater 310 and thesecond heater 320 to generate an aerosol. The aerosol generated withinthe capsule 200 may pass through the second coupler 350 and, optionally,be drawn from the aerosol-generating device 300 via a mouthpiece.

Using the capsules and devices disclosed herein, an aerosol-formingsubstrate may be heated to generate an aerosol. In an exampleembodiment, a method of generating an aerosol may include engaging acapsule 200 between a first heater 310 and a second heater 320. Thecapsule 200 may define internal channels holding an aerosol-formingsubstrate. The method may additionally include heating theaerosol-forming substrate via conduction with the first heater 310 andthe second heater 320. Furthermore, the incoming air entering thecapsule 200 may optionally be heated air so as to also promote a heatingof the aerosol-forming substrate via convection. Thus, theaerosol-forming substrate may be heated conductively and/or convectivelyto generate an aerosol.

Further to the non-limiting embodiments set forth herein, additionaldetails of the substrates, capsules, devices, and methods discussedherein may also be found in U.S. application Ser. No. 16/451,662, filedJun. 25, 2019, titled “CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATINGDEVICES, AND METHODS OF GENERATING AN AEROSOL,” Atty. Dkt. No.24000NV-000522-US; U.S. application Ser. No. 16/252,951, filed Jan. 21,2019, titled “CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES,AND METHODS OF GENERATING AN AEROSOL,” Atty. Dkt. No. 24000NV-000521-US;U.S. application Ser. No. 15/845,501, filed Dec. 18, 2017, titled“VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THESAME,” Atty. Dkt. No. 24000DM-000012-US; and U.S. application Ser. No.15/559,308, filed Sep. 18, 2017, titled “VAPORIZER FOR VAPORIZING ANACTIVE INGREDIENT,” Atty. Dkt. No. 24000DM-000003-US-NP, the disclosuresof each of which are incorporated herein in their entirety by reference.

While a number of example embodiments have been disclosed herein, itshould be understood that other variations may be possible. Suchvariations are not to be regarded as a departure from the spirit andscope of the present disclosure, and all such modifications as would beobvious to one skilled in the art are intended to be included within thescope of the following claims.

1. A capsule for an aerosol-generating device, comprising: a housingdefining inlet openings, outlet openings, and internal channels betweenthe inlet openings and the outlet openings, the internal channelsconfigured to hold an aerosol-forming substrate, the housing configuredto facilitate a heating of the aerosol-forming substrate via conductionso as to generate an aerosol.
 2. The capsule of claim 1, wherein theinlet openings are configured to permit air to enter the capsule, andthe outlet openings are configured to permit the aerosol to exit thecapsule.
 3. The capsule of claim 1, wherein the internal channels areseparate and independent conduits.
 4. The capsule of claim 1, whereinthe housing includes a body section, a first end cap, and a second endcap.
 5. The capsule of claim 4, wherein the first end cap is secured toan upstream end of the body section, and the second end cap is securedto a downstream end of the body section.
 6. The capsule of claim 4,wherein the body section defines the internal channels, the first endcap defines the inlet openings, and the second end cap defines theoutlet openings.
 7. The capsule of claim 6, wherein the first end capand the second end cap are configured to engage with the body sectionsuch that each of the inlet openings of the first end cap is in fluidiccommunication with a corresponding outlet opening of the second end capvia a corresponding internal channel of the body section.
 8. The capsuleof claim 4, wherein the body section includes a corrugated structure anda conductive cover configured to contain the corrugated structure. 9.The capsule of claim 8, wherein the corrugated structure of the bodysection has alternating ridges and furrows defining the internalchannels configured to hold the aerosol-forming substrate.
 10. Thecapsule of claim 9, wherein each of the ridges and furrows has acoplanar surface between a pair of angled surfaces.
 11. The capsule ofclaim 9, wherein the conductive cover is configured to surround theridges and furrows of the corrugated structure.
 12. The capsule of claim8, wherein the corrugated structure has a portion with a cross-sectionresembling a trapezoidal wave.
 13. The capsule of claim 8, wherein theconductive cover is in a form of a box sleeve.
 14. The capsule of claim8, wherein the conductive cover is made of a metal.
 15. The capsule ofclaim 14, wherein the metal includes aluminum.
 16. The capsule of claim1, wherein the housing is configured such that the internal channelsextend along a longest dimension of the housing.
 17. The capsule ofclaim 1, wherein the housing has a length, a width, and a thickness, thelength is greater than the width, the width is greater than thethickness, and the internal channels extend in a direction of thelength.
 18. The capsule of claim 1, wherein the aerosol-formingsubstrate includes a plant material.
 19. The capsule of claim 18,wherein the plant material includes tobacco.
 20. An aerosol-generatingdevice, comprising: a device body defining at least one slot configuredto receive a capsule containing an aerosol-forming substrate; and aheating assembly configured to heat the capsule containing theaerosol-forming substrate to generate an aerosol, the heating assemblyincluding a first heater and a second heater configured to sandwich thecapsule in between so as to heat the aerosol-forming substrate viaconduction.
 21. A method of generating an aerosol, comprising: engaginga capsule between a first heater and a second heater, the capsuledefining internal channels holding an aerosol-forming substrate; andheating the aerosol-forming substrate via conduction with the firstheater and the second heater.